welding through the ages - american welding society 11 welding history ©2013 m. j. greitmann,...

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1welding history©2013 M. J. Greitmann, Hochschule Esslingen

Prof. Dr.-Ing. (IWE) Martin J. [email protected]

Welding through the Ages

Hochschule Esslingenwww.hs-esslingen.de


Personal Bibliography resistance welding

DVS - German Welding SocietyChairman of DVS working group V 3.3„Resistance welding in electronics and precision mechanics”

International Institute of Welding (IIW) Expert of Commission III„Resistance welding, solid state welding and allied joining processes“

Professional / consulting engineer: Greitmann Consulting, www.greitmann.com

www.ip-esslingen.com

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History of welding

(WELDING - A JOURNEY TO EXPLORE ITS PAST)

Bookstore on the Hobart Institute

www.welding.org


Contents

History of welding

Dimesions (macro & micro engineering)

Quality assurance

Numerical simulation

Education & training


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History of welding

(welding and cutting, journal No. 9 (2005))

2600 B.C. – Electrum cup and golden headdresskings grave at Ur (Mesopotamia / today Iraq)

Solder joint

Electrum: 75% Au, 25% Ag


History of welding


2600 B.C. – golden knife daggerkings grave at Ur (Mesopotamia / today Iraq)

Soldering: pellets and twisted wires

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History of welding

Early soldering with charcoal and blow pipe


1330 B.C. – golden death mask of Tut-Ench-Amun (Egypt)


History of welding


Reaction Soldering: 1330 B.C. – golden knife dagger (Egypt)

Solder joint at the knob(soldering metal: Au-Ag-Cu alloy)

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History of welding

Height: about 7.375 m Diameter: 41.6 cm (bottom)

34 cm (top).

Weight: estimated > 6 t

Material: wrought iron C (0.03–0.28)Si (0.004–0.056)P (0.114–0.48)

(www.ias.ac.in/currsci/jun252005/1948.pdf ; www.wikipedia.org )

Iron Age – Forge welding, pieces of wrought iron 310 AD - The iron pillar of Dehli (India)


History of welding

Bronze AgeSmall gold circular boxes were made by pressure welding lap joints together.

Iron Age During the Iron Age the Egyptians and people in the eastern Mediterranean area learned to weld pieces of iron together. Many tools were found which were made approximately 1000 B.C..

Middle Ages (forge welding)During the Middle Ages, the art of blacksmithing was developed and many items of iron were produced which were welded by hammering.

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History of welding

Forging (Solid State Welding)



History of welding

Forging (Solid State Welding)

(Yoshindo Yoshihara, Hiroko Tateno Kapp und Leon Kapp von Kodansha:

The Craft of the Japanese Sword, Intl ( 1.April 1987))

Application:Multilayer material (“Damascus steel”) manufactured by folding and welding by hammering

Cycle 1 2 4 6 8 10

Layers 4 8 32 128 512 2048

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History of welding

Forging (Solid State Welding)Application: Knife blades

( Schmiedewerkstätte Markus Balbach; www.schmiede-balbach.de )

Steel C Si Mn Cr Ni Mo V

90 MnCrV 8 (1.2842) 0.90 2.0 0.4 0.1

45 NiCrMo 16 (1.2767) 0.45 0.25 0.35 1.35 4.05 0.25

X46Cr13 (1.4034)0.42 -0.50

max. 1.0

max.1.0

12.5 -14.5

X55CrMo14 (1.4110)0.48 -0.60

max. 1.0

max.1.0

13.0 -15.0

0.5 -0.8


History of welding

Forging (Solid State Welding)Application: Knife blades

( Schmiedewerkstätte Markus Balbach; www.schmiede-balbach.de )

( www.friedrich-hartkopf.de )

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History of welding

(DVS, WELDING - A JOURNEY TO EXPLORE ITS PAST)

An oxyfuel gas welding process that uses acetylene as the fuel gas. The process is used without the application of pressure (AWS)

1900 Oxyacetylene welding(Charles Picard (1872-1957) inventor of the first oxyacetylene torch)


History of welding


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History of welding


1881 Carbon Arc Welding(Auguste De Mèritens (1834-1898))

The process was carried out in a box with a fixed electrode.


History of welding


18851887

Carbon Arc Welding(N. Benardos & S. Olszewski used an insulated handel)

Carbon Arc Welding uses an arc between a carbon electrode and the weld pool. The process is used with/without shielding or application of pressure (AWS)

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History of welding


1907 Shielded metal arc welding

Oscar Kjellberg (1870-1931)Protecting the arc and the moltenmetal by a covered electrode

Shielded metal arc welding uses an arc between a covered electrode and the weld pool. The process is used with shielding from the deposition of the electrode coveringwithout the application of pressure, and with filler metal from the electrode (AWS)


History of welding


1930‘s Low cost of arc weldingcompared with rivetingand gas welding

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1940 Gas Tungsten Arc Welding(Russel Meredith developed an electric arc method for welding

magnesium)

welding history©2013 M. J. Greitmann, Hochschule Esslingen

History of welding


Gas Tungsten arc welding uses an arc between a tungsten electrode (nonconsumable) and the weld pool. The process is used with shielding gasand without the application of pressure. (AWS)

Heliarc® TIG torchby Linde


History of welding


1940,1945

Gas metal arc weldingdeveloped at Battelle Memorial Institute, Columbus / Ohio

1945: experimental hand-held MIG gun

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Gas metal arc welding uses an arc between a continuous filler metal electrode (consumable) and the weld pool.

The process is used with shielding from an externally supplied gas and without the application of pressure. (AWS)


History of welding


1943 Gas metal arc weldinginventors: C.B. Voldrich, P.J. Rieppel and Howard B. Cary

1948 Jesse S. Sohn & A.N. Kugler:„Shielded-Inert-Gas-Metal-Arc“ process was introduced by theAir Reduction Co. at the AWS show in Philadelphia

1948: Aircomatic® MIG gun


History of welding

(Miller Electric Mfg. Co., www.MillerWelds.com)

Robot welding systemssince 1980

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History of welding



History of welding / 19th century

1857 James Prescott JOULE (UK)

described the possibilities to weld metalsby resistance heating

1866 Werner von SIEMENS (D)invents the dynamo (requirement to commercialproduce electricity / high current)

1879 Thomas Alva EDISON (USA) invention of a technical usable filament bulb

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1877 Elihu THOMSON (USA, 1853-1937), lecturing at Franklin-Institute, Philadelphia experimental work to the fundamentals of resistancewelding

1881 Special machinesIt is known that special machines have been used for manufacturing resistance welded cables welding current: 60 … 100 Asecondary circuit voltage: 20 V



1886 Elihu THOMSON:applied for 2 process patents No. 347140 and 347141 „Apparatus for Electric Welding“Lynn, Massachusetts (USA), (10th August 1886 German Patent DE No. 39765)

Resistance welding(ISO 857-1, Proc. No. 2):

„Welding with pressure in which the heat necessary for welding is produced by resistance to an electrical current flow through the welding zone.“ (today)

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1886 Elihu THOMSON:process patents No. 347140 and 347141 „Apparatus for Electric Welding“

5 primary circuit

4 core (iron)

3 secondary circuit

2 electric main

A current generator (AC)




1886 Elihu THOMSON:process patents No. 347,140„Apparatus for Electric Welding“

or art of electric weldingto join metal wires

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1887 Elihu THOMSONat American Institute Fair, New York




1887 / 88 Nicolai N. NENARDOS(1842-1905, russian scientist)

Resistance spot welding of iron sheet using carbon electrodes.

(Patent DE No. 46776 and No. 46779)

about 1897

KLEINSCHMIDT Use of copper electrodes(The substitution of the carbon electrodeswas basic for further rapid development andapplication of resistance welding)

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1887, 1888

George Westinghouse (1846-1914)Nicola Tesla (1856-1943)

Patents of power generation and distribution (WELDING - A JOURNEY TO EXPLORE ITS PAST)


History of welding

1903 First machine for resistance butt weldingAfter merger betweenAllgemeine Elektricitäts-Gesellschaft (AEG) and Union-Elektricitäts-Gesellschaft (UEG, Berlin) they were owner of the THOMSON-patents.

1906 First resistance spot welding machines are used in the sheet metal forming industry (up to 1910 about 367 machines for spot and seam welding)

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History of welding

1903 Resistance Butt welding machinesfrom E. Thomson


History of welding

1903 Resistance Butt welding machine

(AEG)

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History of welding

1904 Resistance butt welding machine / Type KA IV(Application: chain manufacturing)

(AEG)


History of welding

since 1906 Resistance spot welding

(PECO)

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History of welding

1911… Seam welding

Applications (1929):thin walled tubes and cones(PECO)

Machine with electrodes for short longitudinal welds


History of welding

1911 Seam welding machine / Type 7,5 LN(max. power 15 kW, max. tSUM = 2.5 mm )

One girl welded in 10 h

2400 buckets (t = 0.28 mm)

weld seam length: 300 mm(welding and cutting, journal No. 9 (2005))

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History of welding

1973 Seam welding

Applications:sheet frames, barrels (d = 350 … 640 mm)


History of welding

1980 Seam welding

(PECO, Messer Griesheim GmbH) (Schlatter Industries AG, Application: Radiator)

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History of welding

1916 Cam disk controled flash welding machine(process fundamentals in 1912)

Welded cross section:1930: 10 000 mm2, 1941: 70 000mm2; 1961: 100 000 mm2

(power: 4,5 MVAwelding current: 300 kA frequency: 9 Hz )


History of welding

1929 Flash welding (Application: lokomotive components)


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History of welding

1962… Resistance welding (spot or projection welding)(applications: small parts in fine mechanics and electronics)

(PECO)


History of welding

today Resistance welding in fine mechanics and electronics

(PECO, Messer Griesheim GmbH, MIYACHI Europe GmbH)

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History of welding

1970 … today Development - Welding pressure heads

pneumatic pneumatic + spring servo-motor piezo-electric actuator

(PECO, Messer Griesheim GmbH, MIYACHI Europe GmbH)


History of welding

1970 … today Development – Welding power supply

Alternating current (AC)

Direct current (DC)

Capacitor discharge

Transistor controlled

Inverter technology > 20 000 Hz

Available control modes: current – voltage – power - energy

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1951

19681977 1981 1986

1994

1997

1960

PSI 61C2009:

History of welding

1951 … 2009 Welding Controls from Bosch Rexroth

(Bosch Rexroth)


Diagnostic/operation unit for status check,setting of IP adress a.o.

Process regulation / monitoring integrated:Process interfaces for current, voltage and force, Adaptive UI-regulator and force supervision on board

USB Interface for local programming and

Ethernet IP / ProfiNet for central programming and operation on board

(Bosch Rexroth)

History of welding

1951 … 2009 Functionality of Inverter Control PSI61C

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History of welding

today Process: control - documentation - inspection


History of welding

today Process: control - documentation - inspection

Parameter:Component geometrySliding movement

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Widerstandsschweißen HeuteWiderstandsschweißen 1930

History of welding

since 1930 Resistance spot weldingin car body manufacturing

(Fronius)


X

Application: spot welding aluminium

70 m of process metal band afford 5 000 – 10 000 repeatable spot welds with one elektrode (no weld spatter).

History of welding

today Car body manufacturingSystem: DELTA SPOT (Fronius)

(Fronius)

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12.5kA

conventional DeltaSpot

Source:(Fronius)

today Car body manufacturing System: DELTA SPOT (Fronius)

History of welding


History of welding

125 years Resistance welding(since the THOMSON patents)

51 years Laser beam technology

20 years Friction stir weldig

Anniversaries in 2011

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History of welding

since 1960 Laser Beam Technology

(TRUMPF Laser)

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History of welding

Theory of stimulated Emission

(Albert Einstein)

1. Maser( Microwave Amplification by Stimulated Emission of Radiation )

(Charles H. Townes)

1. Gas laser

(A. Javan)

He - Ne

= 1,15cm

12. Dezember

1.(Ruby)-Laser

(Light Amplification by Stimulated Emission of Radiation )

(Theodore Maiman)

16 Mai

1. Neodymiumlaser

(L.F. Johnson)

Science-Fiction

1917 1954 1960 1962

1. red He-Ne Laser(A. White)

= 633nm

1960

1917 - 1962 THEORY MASER LASER

(TRUMPF Laser)


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1. CO2 - Laser

(C. Kumar, N. Patel)

1. Nd:YAG Laser

(J.E. Geusic)

1. TRUMPF combinedStamping-Laser-machine

TRUMATIC 180 Lpower: 500 - 750W

1. TRUMPF CO2 - Laser

TLF1000 power: 1kW

1. Argonlaser

(W. Bridges)

„Goldfinger“ (1964)

C. Haas developedfirst Laser-light cable for materials processing

1964 1971 1979 1985

Begin of Nd:YAG Lasertechnology

Fa. C. Haas GmbH

History of welding

1964 - 1990 Development of LASER technology

(TRUMPF Laser)


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One melt two separate melts

∆x

2008 LASER-ARC-HYBRID WELDING

Nd:YAG-Laser-MIGVweld: 40 mm/s

Shielding Gas: Argon, 12l/min

Filler wire: SG-AlSi5d = 1,6 mm

Base metal: EN AW-AlMg3Mn, t = 3,5 mm

(Höfer)

History of welding


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Material: AlMgSi1

Patent – process (TWI, 1992)

Friction stir welding (MPA Stuttgart, 1995)

1991 Friction Stir welding

History of welding


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welding machine (ESAB FSW Legio-3ST) friction stir seam weld

History of welding

(MPA Stuttgart)


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Tool- and processing parameter

- tool material

- shoulder diameter ()

- pin geometry

- penetration (t)

- overlap (u)

- tilt angle ()

- number of revolutions (n)- welding speed (v)

- downward force (F)

- clamp forces

F

History of welding


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Advantages

- simple and robust process

- simple joint preparation

- no fused-on spatters, fume or dust,

- no impact on environment

- no inert protective gas

- low power requirement

- low distortion of the welded parts

- very good mechanical behaviour of the welds

- material mix of different aluminium alloys

welding positions

History of welding


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65

50

60

70

80

90

100

110

-20.0 -15.0 -10.0 -5.0 0.0 5.0 10.0 15.0 20.0

Distance from butt joint assembly [mm]

Har

dn

ess

HV

1

EN AW-6082

EN AW-5083

welding seam and tool

macro-examination specimen

hardness continuum

strength reduction due to solution of precipitates

Application: Aluminium

History of welding


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Application: Audi R8 - Friction stir welded closing plate of the centre tunnel after forming

(Audi AG, Riftec GmbH)

material: EN AW-6181 T4, sheet thickness t: 1.7 mm / 2.4 mm

History of welding


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Volvo XC 90 with 19” hybrid wheel

History of welding


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Principle for Hybrid Wheel manufacturing

History of welding


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Friction Stir Weld

History of welding



Dimensions of welding

(MPA Stuttgart)

coating laser beam welding

resistance spot welding

narrow gap welding

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Multilayer weldment (Pressure vessel components)

(MPA Stuttgart)

t = 270 mmabout 420 weld layers



Narrow gap weldingApplication: big components

(MPA Stuttgart)

200

mm

t = 200 mmabout 120 weld layers

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Electron beam weldingApplication: big components

(MPA Stuttgart)

150

mm

70 m

m



Flash welding (ISO 857-1 Proc. No. 24)Application: welded rails welded cross section area: approximately 8000 mm2

(Schlatter Industries AG)

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Resistance butt welding (ISO 857-1 Proc. No. 25)Application: chainwelded cross section area: 150 mm2

(RUD)



Spot welding (ISO 857-1 Proc. No. 21) Application: car body manufacturing, sheet frameswelded cross section area: 20 mm2

(Krause,BAM, MPA Stuttgart)

in Germany (1997):

75 000 000 spot welds/day

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Projection welding (ISO 857-1 Proc. No. 23)Application: wire cross sections welded cross section area: 80 … 0.5 mm2

(Schlatter Industries AG, MPA Stuttgart)NiTi-wires



Parallel gap welding Application: solar components, sensor systemswelded cross section area: 0.5 mm2

(PECO, MIYACHI Europe GmbH)

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Projection welding (ISO 857-1 Proc. No. 23)Application: electrical contacts welded cross section area: 25 mm2 … 0.1 mm2

(Prym INOVAN GmbH)

Geometry: 0.13 x 0.30mm Materials: 0.5µm Au diffusion

PdRu10 CuNi30Fe



Projection welding (ISO 857-1 Proc. No. 23)

Application: thin (enamelled) wireswelded cross section area: 0.08 mm2

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100

200

300

400

600

Wid

erst

and

0 40 80 120 160 ms 240Zeit

H 320 LAH 320 LA ZE50/50H 320 LA ZE50/50+BZ

mechanical characteristic

(F,m,c,D)

welding current(control)

base metal (E, Re, HV, cp, , )

surface (coating, topography Rz)

electrode (material, geometry, Rz, wear,

water cooling)

Quality criterions for spot welds: (mictrostructure, nugget diameter,

strength, toughness, surface...)

Quality assurance


Quality assurance

Process analysis (video) Metallography(INSTYTUT SPAWALNICTWA, GLIWICE)

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Quality assurance

1929: Dr.-Ing. Dr. iur. Felix Goldmann (Doctoral thesis, Technische Hochschule München)

flash weld (iron) mash seam weld (iron)


Quality assurance


spot weld (stainless steel)

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Quality assurance

1929: Dr.-Ing. Dr. iur. Felix Goldmann (doctoral thesis, Technische Hochschule München)

iron / steel (butt weld) iron / steel (spot weld)


Quality assurance


Zinc coated iron sheets iron sheets with Al-interlayer

iron sheet

Al-interlayer

iron sheet

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Quality assurance

1929: Dr.-Ing. Dr. iur. Felix Goldmann (doctoral thesis, Technische Hochschule München)

Copper / Brass Bronze / Brass

Resistance spot welds

(MPA Stuttgart,1998)


Zeiss Auriga Crossbeam

Gemini Elektronen-strahl-Säule

FIB-Säule (Ionenstrahl) EDS

Detektor Inlens-Detektoren

SE-SI-Detektor

große Proben-kammer

Detektorkonfiguration

EBSD-System

Elektronenstrahl

Schottky Feldemitter

1,0 nm @ 15 kV

1,9 nm @ 1 kV

Ionenstrahl

Gallium-Ionenquelle

< 7 nm @ 30 kV

Quality assurance Scanning electron microscopy (SEM)

(MPA Stuttgart)

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TEM (Stahl)

Schweißverbindung

EFTEM (Stahl VM12)

Elektronenbeugung

(MPA Stuttgart)

Quality assurance Scanning electron microscopy (SEM)


Mg

Al

Si

keV0

10 00

20 00

30 00

40 00

50 00

0 10 .0 0

AA 6082

Mg

Al

SiMn

MnFe

Fe keV0

10 00

20 00

30 00

40 00

50 00

60 00

70 00

80 00

0 10.00

SEM examination

Thermal simulation (Thermo-Calc)

Results: Phase diagramme melting of intermetallic phases

Al

Mg

Si

FeMn

Al

SiMg

0

0.2

0.4

0.6

0.8

1.0

MO

LE_F

RA

CTI

ON

SI

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

MOLE_FRACTION MG

System: Al-Mg-Si (at 773 K / 500 °C)

Mg2Si

Si

MgAl

Quality assurance material science – thermal simulation

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0 mm

+10 mm +20 mm

+25 mm

Steel:

HCT700T (TRIP 700)

Experimental thermal simulationweldability

(MPA Stuttgart)


(Al / 15vol.%Al2O3)

50 m50 µm

Microstructure and FE-mesh

Quality assurance microstructure mechanics

(MPA Stuttgart)

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Crack growth in AA6061/Al2O3 (tensile load)

0% 0,4% 1,1% 3,1% 4,6%

Zug

0,4% 1,1%

(MPA Stuttgart)

Quality assurance microstructure fracture mechanics (FEM)


Quality assurance Non-destructive testing (NDT)

(GE; phoenix|x-ray Systems + Services GmbH)

X-ray inspection and computed tomography (CT)

BGA solder joints (CT volume animated)

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Quality assurance Non-destructive testing (NDT)

(GE; phoenix|x-ray Systems + Services GmbH)

Laser beam weld (X-ray; CT volume animated)


Quality assurance video based process analysis

Resistance butt welding (different colour filter)

frame red

green blue

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Quality assurance Process analysis – Thermography

Stahl

A A

1100

900

800

700

600

°C

500

600

700

800

°C

1000

Tem

pera

tur

20 30 40 Pixel 60

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 mm 7

Länge

kaltwarm

Resistance butt welding

heat image temperature distribution


Resistance spot welding (material: DC04; t1=0.8mm / t2=1.5 mm)

Quality assurance numerical process analysis

Spotwelder (1997)

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Resistance WeldingMODEL FOR NUMERICAL ANALYSIS

Geometry Material data ( Young’s modulus, µ, ... )

Electrode force

Structure mechanicModel

Stress distribution

Deformation

Temperature-

fieldDesign

Welding current Material data ( cp, Rk,, ... )

Electric-thermalModel

Temperature distribution

Numerical process analysis


Mechanical Model - Machine


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Electrical model – Contact resistance


Database

Material Resistance

and Contact Resistance

20

40

60

80

100

120

140

µ

180

Ele

ctric

al R

esis

tanc

e

0 400 800 1200 °C 2000

Temperature

RAlloy ( t1 = t2 = 1.25 mm; AlMg0.4Si1.2 )RContact Resistanc ( Model: MPA Stuttgart )RAlloy + RContact Resistanc

Temperature

Co

nta

ct

Re

sis

tan

ce


52


Measuring transitent resistance - experimental setup

DC06 Blank zwei Bleche 3000N

1440

1500

1560

1620

0 10 20 30 40 50 60

Zeit [s]

Wid

ers

tan

d [

µO

hm

]

R1R3R6R4R2

Contact resistance

(MPA Stuttgart)


Measurement - transition resistance

ISO 18594

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0 1 2 3 4 5 6 7 8

CuFe2P, t = 0,6 mmCuFe2P, t = 0,4 mmCuFe2P, t = 0,2 mm

CuNi3Si1Mg, t = 0,6 mmCuNi3Si1Mg, t = 0,4 mmCuNi3Si1Mg, t = 0,2 mm

CuNiCo1Si, t = 0,4 mmCuNiCo1Si, t = 0,2 mm

CuSn8, t = 0,6 mmCuSn8, t = 0,4 mmCuSn8, t = 0,2 mm

CuZn37, t = 0,6 mmCuZn37, t = 0,4 mmCuZn37, t = 0,2 mmE-Cu58, t = 0,6 mmE-Cu58, t = 0,4 mmE-Cu58, t = 0,2 mm

CuCrAgFeTiSi, t = 0,4 mmCuCrAgFeTiSi, t = 0,2 mm

Übergangswiderstand / m

Transition resistance (copper alloys)

(MPA Stuttgart)Transition resistance


Data base

physical material properties

electrical resistivity thermal conductivity heat capacity cp


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Data base

mechanical material properties



Data basemechanical material properties


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Numerical process analysisHot staking process

Resistance welding of commutator segments with hook geometry



Resistance welding of commutator segments

slot geometry hook geometry

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1984 R. Schwab (doctoral thesis): numerical simulation of Hot Staking process

commutator segments with slot geometry



1984 R. Schwab (doctoral thesis): Numerical simulation of Hot Staking process

commutator segments with slot geometry

temperature field temperature-time-curve

(Schweißen und Schneiden, 38 (1986), Heft 8, S. 365-369)

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1990 P. M. Schäfer (doctoral thesis): numerical simulation of Hot Staking process

commutator segments with hook geometry



1990 P. M. Schäfer (doctoral thesis): numerical simulation of Hot Staking process

commutator segments with hook geometry

temperature field (time: 20 ms and 100 ms)

(DVS-Berichte, Band 89)

58


Numerical process analysisHot staking process (2012)

(Lanier)

Resistance welding of commutator segments with hook geometry


Numerical process analysiselectrotecnic application

wire termination

59


W-Elektrode

W-Elektrode

CuSn6 -Gabel

CuL -Draht

Numerical process analysiselectrotechnic application

FEM Model & Process

(Dötzer)



(Dötzer)

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119welding history©2013 M. J. Greitmann, Hochschule Esslingen Projection Welding - Joint Geometry

Stress distribution(von Mises)


Projection welding



(Kußmaul, Blind, Zeng, Greitmann, Schäfer, 1991)

61



Process & mechanical model




Calculated projection deformation and temperature distribution


Database: Temperature-dependent stress-strain behaviour of the used projection

62


calculated movement and temperature distribution


(Vichniakov, Herold, Greitmann, Roos, 2002 in Mathematical modelling of the weld phenomena )

2001 Alexei Vichniakov (doctoral thesis): numerical simulation of projection welding


(Bschorr, Cramer, SLV München NL der GSI mbH)

Numerical process analysisprojection welding of srew nuts

Projection welding: srew nuts onto high strength steel sheet

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(Bschorr, Cramer, SLV München NL der GSI mbH)

Numerical process analysisprojection welding of srew nuts

Optimization of srew nut geometry

old new


• Square nut welding

Numerical process analysisprojection welding

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circular saw

stellite hard facing

1920 1960

Brazing (CuAg solder)

resistance welding Laser beam welding

1985 1992

band saw(grinded)

padsaw

padsaw

Numerical process analysisCarbide tipped saw blade


Comparison of calculated temperature field and metallographic cut of a hard metal / steel weldment

Numerical process analysisCarbide tipped tools (1990)

1990 Martin J. Greitmann (doctoral thesis)

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Comparison of calculated temperature field and metallographic cut of a hard metal / steel weldment

Numerical process analysisCarbide tipped tools (1990)

1990 Martin J. Greitmann (doctoral thesis)


FE-Model (geometry)

FE-Model

ElektrodeTrägersegment

HartmetallElektrodenbacken

Experimental setup

Numerical process analysisCarbide tipped band saw (2000)

(Greitmann, Wink)

66


Current distribution

A

A

Temperature field

time: 70 ms

Videoclip


(Greitmann, Wink)


Carbide tipped saw band

Hartmetall

Sägeband


(Greitmann, Wink)

67


Längsschnitt

Realtime-Bildfolgezeit

5 ms

Konturabstand 100 °C

Temperatur-bereich

0°C bis 2000 °C

nach 70 msVideoclip


(Greitmann, Wink)


Temperature distribution for a max. temperature of aprox. 1500 °C in the welding zone

°C

Hartmetallüberstand: 0 mmSägeblattüberstand: 7,65 mmZeitpunkt: 145 ms

Hartmetallüberstand: 0,8 mmSägeblattüberstand: 7,65 mmZeitpunkt: 130 ms

Hartmetallüberstand: 0,8 mmSägeblattüberstand: 1,0 mmZeitpunkt: 145 ms


(Greitmann, Wink)

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APPLICATION

Spot Welding

Numerical process analysisresistance spot welding


Numerical process analysisresistance spot welding (1996)

69


Example: Variable sheet thickness



Temperature distribution


(Greitmann, Wink)

70


local temperature–time history

0

200

400

600

800

1000

1200

1400

1600

1800

0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0

Time

Tem

per

atu

re

Position 1 Position 2






Position 13

Sheet material: DX54D+Z100 Sheet thickness: 1,0 mmElektrode material: CuCrZrDome radius: 40 mmElektrode force: 2,5 kNWelding current: 8 kACurrent-flow time: 240 ms

s

°C

current flow time

?


(Greitmann, Wink)


Time /s

Tem

per

atu

re /

°C

0

200

400

600

800

1000

1200

1400

1600

1800

0,0 0,1 0,2 0,3 0,4 0,5

Time

Te

mp

era

ture

°C

Electric Joule heating: AC currentCooling: nitrogen cover gas

Experimental thermal simulation 1250 °C / 0.5 s, Steel: HCT700T (TRIP 700)


(Greitmann, Wink, Kießling)

71


Fe -Rechnung

Steel:

HCT700T (TRIP 700)

Time-Temperature-Transformation

Tem

per

atu

re /

°C

Time / s


(Greitmann, Wink, Kießling)


Microstructure and hardness distribution

Spot welding 1.5 mm DP600 steel sheets

Measured micro hardness comparing to simulated hardness near the weld nugget

Macrograph of real weld comparing to simulated weld nugget and martensite distribution


72


Weld Schedule Specifications with optimal welding parameters

Weld PlanningWeld Schedule Specification


Use of numerical Analysis

• Optimization of joint geometry

• Weldability of different materials

• Weldability of metallic coatings

• Optimization of joining parameters (tool geometry, welding current and electrode force)

Resistance welding Numerical analysis of weldability

73


Education and Training

(DVS, WELDING - A JOURNEY TO EXPLORE ITS PAST)

1910‘s Training of weldersSixteen courses of welding at various institutions in the German empire, at nearly more than 100 locations.

Also England & France had established government welding schools

1915 Army Welding School Kenosha, Wisconsin



(WELDING - A JOURNEY TO EXPLORE ITS PAST) (Hobart Institute of Welding Technology)

1925 Hobart Brothers Companyfirst „Arc Welder“

1930 First 80-page training booklet„Electric Arc Welding“ by Wilbur J. Chaffee

74



Welding simulation

(Lincoln Electrin)



1897 German Welding Society (DVS)

1919 American Welding Society (AWS) was founded as a multifaceted, nonprofit organization with a goal to advance the science, technology and application of welding and related joining disciplines

(DVS, AWS)

75



Thank you for your attention !

An efficient welding technology

combined with best trained welders

will open the door for going green.


Welding through the Ages References

/1/ ODERMATT, André, A.:WELDING – A JOURNEY TO EXPLORE ITS PAST.Hobart Institute, www.welding.org

/2/ PUSCHNER, M.:5 Jahrtausende Schweißen – Eine Frühgeschichte der Schweißtechnik.ISBN: 978-3-87155-714-9, DVS Media GmbH, Deutscher Verlag für Schweißtechnik GmbH, Düsseldorf (1986)

/3/ GOLDMANN, Felix:Die elektrische Widerstandschweißung im Lichte der Metallographie.Dissertationsarbeit, Technische Hochschule München, Druck von Friedr. Vieweg & Sohn AG, Braunschweig (1930)

/4/ DVS:Jubiläumsband „100 Jahre DVS“ DVS Media GmbH, Artikelnummer: 600050, Deutscher Verlag für Schweißtechnik GmbH, Düsseldorf (1997)

/5/ DE FODOR, Etienne: Die elektrische Schweissung und Löthung – Nachdruck der 1892 erschienenen Originalausgabe. ISBN 13: 978-3-87155-703-3, DVS Media GmbH, Deutscher Verlag für Schweißtechnik GmbH, Düsseldorf (1980)

/6/ PETER, H.-J.: Löten – eine „Ur“-alte Geschichte.Schweißen und Schneiden Bd. 57 (2005) No. 9, p. 512-520, DVS Media GmbH, Düsseldorf

/7/ BEHNISCH, Hellmuth & AICHELE Günter:Die Schweißtechnik im Wandel der Zeiten.ISBN: 978-3-87155-794-1, DVS Media, Deutscher Verlag für Schweißtechnik GmbH, Düsseldorf (2006 )

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